Conductive joint formed by electron beam welding and method thereof

ABSTRACT

An arrangement is provided for welding together current carrying members of an electrical distribution device that are made of similar conductive material. The arrangement includes an electron beam gun capable of generating an electron beam sufficient to penetrate and heat the material, thereby providing mixing of the material to form a joint which is constructed substantially of a portion of each of the current carrying members.

RELATED APPLICATION

This application is a continuation in part of U.S. application Ser. No. 08/978,941 filed Nov. 26, 1997, now abandoned which is a division of U.S. application Ser. No. 08/741,091 filed Oct. 30, 1996, now U.S. Pat. No. 5,798,495 that is incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates generally to joining conductive materials together in electrical distribution equipment such as busway and, more particularly, to an arrangement for electron beam welding similar electrically conductive material to form a highly conductive joint. In addition, the invention also relates to a method for electron beam welding together similar conductive material.

BACKGROUND OF THE INVENTION

The present method for joining similar conductive material components such as busbars, in electrical busway is by gas-metal arc welding (GMAW). This method of joining the components together causes excess weld metal to form on the busbars which requires additional process time and cost for the removal thereof. Additionally, the GMAW method requires the use of a filler wire which has a lower conductivity than the busbar material, thereby creating a joint that is lower in conductivity than the busbars that are being welded together. This lower conductivity causes the resistivity of the joint to be higher than the original material and, hence, increases the heat rise in the joint when current is drawn through.

Accordingly, there is a distinct need for an improved arrangement and method to join similar conductive material that will provide a joint that is substantially as conductive as the original material. Additionally, the improved arrangement will not produce excess weld metal on the material, thereby eliminating the need to remove this excess weld metal and, hence, decreasing the process time and cost required to weld the material together.

SUMMARY OF THE INVENTION

The present invention provides an improved method to join similar conductive components in electrical distribution equipment which provides decreased process cycle time and increased conductivity in the joint.

The present invention provides an electrical distribution device including a first current carrying member made of a first material and partially defined by a surface and a second current carrying member made of a second material and partially defined by a surface. A joint is substantially located between the first current carrying member and the second current carrying member such that the joint is formed by electron beam means traversed between the first and second current carrying members at a first predefined energy level and a first predefined speed to penetrate, heat, and mix the first and second materials of the respective first and second current carrying members. The joint is further formed by the electron beam means subsequently traversed between the first and second current carrying members at a second predefined energy level and a second predefined speed to heat and melt the first and second materials of the joint to a level at or below the surfaces of the of the respective first and second current carrying members preventing the buildup of excess weld material at the joint and providing a finish to the surface of the weld material, the joint being constructed substantially of a portion of the first material of the first current carrying member and a portion of the second material of the second current carrying member.

In accordance with a preferred embodiment of the present invention, an arrangement is provided for welding together current carrying members of an electrical distribution device. The current carrying members are constructed from similar conductive material. The arrangement includes an electron beam gun capable of generating an electron beam sufficient to penetrate and heat the material, thereby providing mixing of the material to form a joint which is constructed substantially of a portion of each of the current carrying members.

The present invention also provides a method for welding current carrying members of a metal alloy material. Each of the members has a surface. The method includes: traversing an electron beam between a first and second current carrying members at a first predefined energy level and a first predefined speed to penetrate, heat, and mix the first and second materials of the respective first and second current carrying members to form a joint; and subsequently traversing between the first and second current carrying members at a second predefined energy level and a second predefined speed to heat and melt the first and second materials of the joint to a level at or below the surfaces of the of the respective first and second current carrying members preventing the buildup of excess weld material at the joint and providing a finish to the surface of the weld material, the joint being constructed substantially of a portion of the first material of the first current carrying member and a portion of the second material of the second current carrying member.

Also according to this invention, current carrying components in an electrical distribution device are welded together using a process which includes the steps of disposing busbar components adjacent to one another, activating an electron beam welding gun to generate an electron beam and passing the electron beam past the busbar components to form a joint.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and advantages of the invention will be apparent from the following detailed description and the accompanying drawings in which:

FIG. 1 is an isometric drawing of an electron beam welding arrangement for joining similar conductive material together according to the present invention;

FIG. 2 is an isometric drawing of an electron beam welding arrangement for joining aluminum alloy material together according to the present invention;

FIG. 3A is an isometric side view of two workpieces before being welded by the present invention; and

FIG. 3B is an isometric side view of the two workpieces in FIG. 3A after being welded by the present invention illustrating the conductive joint formed by two passes of electron beam welding.

While the invention is susceptible to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the drawing and will be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular form described, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For a better understanding of the present invention together with other and further advantages, and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above-described drawings.

FIG. 1 shows a preferred embodiment of an arrangement, designated generally by the reference character 10, in accordance with the present invention for joining current-carrying members in an electrical distribution device, such as the type shown in U.S. Pat. No. 4,673,229 entitled “Electrical Distribution System with an Improved Housing” which is assigned to the same assignee as the present application and the disclosure therein is incorporated herein by reference in its entirety. Current-carrying members, such as busbars, in electrical distribution devices of this type are typically joined together by traditional metal arc welding processes that cause excess weld material to form on the busbars. Additional process time is required to remove this excess weld material, thereby increasing the cost of the process. Additionally, traditional metal arc welding processes require the use of filler wire to assist in welding the busbars together. This filler wire has a lower conductivity than the busbars, thereby creating a joint that has a lower conductivity than the busbars. These problems are addressed by the arrangement 10 that includes an electron beam gun 12, which is capable of generating an electron beam 14, and a vacuum chamber 16. The gun is preferably implemented with a 12 kW at 60 kV electron beam gun available from Wentgate Dynaweld Inc. of Agawam, Mass. The chamber 16 includes vacuum hoses 26 and 28 secured thereto and a cover (not shown) for sealing the chamber 16 so that a vacuum may be created in the chamber 16. The gun 12 is secured to the cover (not shown) or the chamber 16 by means of an appropriate securing arrangement (not shown) that allows the gun 12 to move without a significant loss of vacuum in the chamber 16. For example, a motor could move the gun 12 on a slider within a sliding seal. A first busbar 20 and second busbar 22, comprised of similar conductive material, such as a copper alloy, are disposed within the chamber 16 and are positioned adjacent to one another to define a joint 24. A focus coil (not shown) disposed in the gun 12 focuses the electron beam 14 into the joint 24 causing the heat generated by the electron beam to be localized to an area immediately surrounding the joint 24.

The process for welding together the busbars 20 and 22 will now be described. The first and second busbars 20 and 22 are secured to a conventional fixture (not shown) by conventional clamps (not shown) in the chamber 16. After the busbars are secured to the fixture, the cover (not shown) is secured onto the chamber 16 and air is withdrawn from the gun 12 and chamber 16 through the hoses 28 and 26, respectively, to create a vacuum. For example, the vacuum may be at a level in the range of 10⁻¹ Torr to 10⁻⁵ Torr and preferably at 5×10⁻². The gun 12 is then activated and energy in the form of the electron beam 14 is transmitted therefrom. The gun 12 is then moved in the direction of arrow X so that the electron beam 14 traverses the joint 24. It is to be understood that the electron beam 14 may remain stationary and the joint 24 may move under the electron beam 14. As the electron beam 14 moves over the joint 24, the busbars 20 and 22 are welded together at the joint 24 to form a weldment 30. The energy level at which the gun 12 operates and the speed at which it traverses the joint 24 are sufficient to allow the electron beam 14 to penetrate and heat the busbar material near the joint, thereby providing mixing of the busbar material to form the weldment 30. For example, it has been found that the gun 12 is best operated at an energy level of 70 mA at 60 kV while it traverses the joint 24 at a speed of 15 in/min. during this first weld pass. It should be noted that the energy level that the gun 12 operates and the speed that the gun 12 traverses the joint 24 are directly associated with one another. The energy level may be changed provided the speed is correspondingly changed. For example, if the energy level is increased, the speed must be increased and if the energy level is decreased, then the speed must be decreased.

After the above-described weld pass, a second weld pass is utilized to provide a cosmetic finish on the weldment 30. The gun 12 traverses the weldment 30 to provide a cosmetic finish that eliminates the need to grind excess weld material from the weldment 30 and busbars 20 and 22. The level at which the gun 12 operates and the speed at which it traverses the weldment 30 are sufficient to allow the electron beam 14 to heat the weldment 30 to cause the weldment material to melt and flow to a level which is flush to or less than the surface of the busbars 20 and 22 while limiting excess heat build-up in the weldment 30 so that it does not collapse. It has been found that the gun 12 is best operated at an energy level of 70 mA at 60 kV while it traverses the weldment 30 at a speed of 30 in/min during this second weld pass.

After the above described first and second passes, the chamber 16 is vented and the cover (not shown) is removed therefrom. The first and second busbars 20 and 22 are then turned over so that the other side of the busbars 20 and 22 may be welded together. The cover (not shown) is secured to the chamber 16 and then the air is withdrawn from the gun 12 through the hose 28 and from the chamber 16 through the hose 26 to create a vacuum. The joint 24 on the opposite side of the busbars 20 and 22 is then welded using the above-described method. After this second welding process is completed, the chamber 16 is vented and the cover 18 is removed to provide access to the busbars 20 and 22.

The above-described arrangement and method provides a joint that has less excess weld material than the gas arc welding process. Additionally, this method does not require the use of a low conductive filler wire to create the joint, thereby providing a welded joint that is just as conductive as the busbars themselves.

According to another preferred embodiment, the busbars 20 and 22 are comprised of an aluminum alloy, preferably 6101 aluminum alloy. FIG. 2 shows a high silicon alloy, preferably 4047 aluminum alloy, shim 32 disposed in the joint 24 between the first and second busbars 20 and 22 prior to the welding procedure to prevent the weldment 30 from hot cracking. The high silicon in the shim 32 causes the weld material in the weldment 30 to be ductile during solidification thereof, thereby preventing the weldment 30 from hot cracking. The thickness of the shim 32 is large enough to prevent hot cracking in the weldment; however, it is thin enough to allow proper melting and mixing of the shim 32 and the busbars 20 and 22 during the welding process. It has been found that the desired performance of the shim 32 is achieved when its thickness is in the range of 0.005 in. to 0.100 in. and is preferably 0.030 in. thick.

The process for welding together these aluminum busbars will now be described. The first and second busbars 20 and 22 are secured to a conventional fixture (not shown) by conventional clamps (not shown) in the chamber 16. The shim 32 is placed in the joint 24 between the busbars 20 and 22. The cover (not shown) is then secured onto the chamber 16 and air is withdrawn from the gun 12 and chamber 16 through the hoses 28 and 26, respectively, to create a vacuum. For example, the vacuum may be at a level in the range of 10⁻¹ Torr to 10⁻⁵ Torr and preferably at 5×10⁻². The gun 12 is then activated and energy in the form of the electron beam 14 is transmitted therefrom. The gun 12 is then moved in the direction of arrow X so that the electron beam 14 traverses the joint 24. It is to be understood that the electron beam 14 may remain stationary and the joint 24 may move under the electron beam 14. As the electron beam 14 moves over the joint 24, the busbars 20 and 22 and the shim 32 are welded together at the joint 24 to form the weldment 30. The energy level at which the gun 12 operates and the speed at which it traverses the joint 24 are sufficient to allow the electron beam 14 to penetrate and heat the shim 32 and the busbar material of the busbars 20 and 22 near the joint, thereby providing mixing of the shim and busbar material to form the weldment 30. For example, it has been found that the gun 12 is best operated at an energy level of 30 mA at 60 kV while it traverses the joint 24 at a speed of 30 in/min. During this first weld pass. It should be noted that the energy level that the gun 12 operates and the speed that the gun 12 traverses the joint 24 are directly associated with one another. The energy level may be changed provided the speed is correspondingly changed. For example, if the energy level is increased, the speed must be increased and if the energy level is decreased, then the speed must be decreased.

After the above-described weld pass, a second weld pass is utilized to provide a cosmetic finish on the weldment 30. The gun 12 traverses the weldment 30 to provide a cosmetic finish that eliminates the need to grind excess weld material from the weldment 30 and busbars 20 and 22. The level at which the gun 12 operates and the speed at which it traverses the weldment 30 are sufficient to allow the electron beam 14 to heat the weldment 30 to cause the weldment material to melt and flow to a level which is flush to or less than the surface of the busbars 20 and 22 while limiting excess heat build-up in the weldment 30 so that it does not collapse. It has been found that the gun 12 is best operated at an energy level of 30 mA at 60 kV while it traverses the weldment 30 at a speed of 30 in/min during this second weld pass.

After the above described first and second passes, the chamber 16 is vented and the cover (not shown) is removed therefrom. The first and second busbars 20 and 22 are then turned over so that the other side of the busbars 20 and 22 may be welded together. The cover (not shown) is secured to the chamber 16 and then the air is withdrawn from the gun 12 through the hose 28 and from the chamber 16 through the hose 26 to create a vacuum. The joint 24 on the opposite side of the busbars 20 and 22 is then welded using the above-described method. After this second welding process is completed, the chamber 16 is vented and the cover 18 is removed to provide access to the busbars 20 and 22.

The above-described arrangement and method for welding together busbars made of aluminum provides a joint that has less excess weld material than the gas arc welding process. The shim 32 is thin enough so that its effect on the conductivity of the weldment 30 is negligible. Additionally, this method does not require the use of a low conductive filler wire to weld busbars together, thereby providing a welded joint that is substantially as conductive as the busbars themselves.

The present invention can be advantageously used to form a conductive joint between two workpieces that do not butt together. The conductive joint formed by the present invention having significantly greater conductivity and strength compared to the hermetic joint formed by prior art processes. FIG. 3 illustrates a first workpiece 60 such as a current carrying member having one end 62 that illustrates a non-square shape typically fabricated by a mill. A second workpiece 64 has an end 66 that illustrates a shape simply sheared to the desired length by cutting. The end 66 has a break portion 68 and a shear portion 70 which is typical, particularly for workpieces made of aluminum. The end 66 has not been premachined or prepared in any way before the formation of the joint. The approximate diameter, for the sake of this example and not for limitation, is about 0.25″.

FIG. 3B illustrates the welds 80 and 82 formed by two passes of the electron beam at high energy. The two welds 80 and 82 fully penetrate between the two workpieces 60 and 64. The welds 80, 82 formed by the high-energy penetration passes avoid the trapping of air in the welds between the two workpieces 60, 64. Through manipulation of the electron beam causing an oscillation, two subsequent passes of the electron beam forms two cosmetic welds 84 and 86 which provide edges 88 flush with the exterior surface 90 and 92 of the two respective workpieces 62, 64. No machining of the workpieces 62 and 64 is required by the present invention to remove excess powder or weld material. A smooth, flush surface is provided by the present invention without post-welding processing saving time and expense.

The present invention provides complete joint penetration for a conductive, strong weld unlike the partial penetration of the prior art that provides a weaker, hermetic joint. The present invention eliminates the need for machining or other preparation of the workpieces before welding as well as needing any finishing work after the welding process. The present invention is useful for welding many materials other than aluminum to aluminum such as copper C11000 (ETP) to copper C11000 (ETP).

From the foregoing detailed description, it can thus be seen that the present invention provides an improved arrangement and method to join similar conductive material which provides decreased process cycle time and increased conductivity in the welded joint. For example, the improved arrangement provides a welded joint that is free of excess weld material that commonly occurs during traditional metal arc welding processes. Obviously, this eliminates the need to remove the excess weld material after the welding process, thereby reducing the time and cost of the welding process. The improved arrangement also provides a welded joint that is more conductive than a joint created by a metal arc welding process, thereby producing a lower heat rise when current flows through the joint. Tight joint tolerances are also provided by the present invention; again, without post weld machining.

The foregoing description is not limited to the specific embodiment herein described, but rather by the scope of the claims that are appended hereto. For example, although the invention has been described with reference to welding the busbars in a vacuum, the process may be adapted to welding the busbars out of the vacuum. 

What is claimed is:
 1. An electrical distribution device comprising: a first current carrying member made of a first material and partially defined by a surface; a second current carrying member made of a second material and partially defined by a surface; and a joint substantially located between the first current carrying member and the second current carrying member such that the joint is formed by electron beam means traversed between the first and second current carrying members at a first predefined energy level and a first predefined speed to penetrate, heat, and mix the first and second materials of the respective first and second current carrying members and the joint further formed by the electron beam means subsequently traversed between the first and second current carrying members at a second predefined energy level and a second predefined speed to heat and melt the first and second materials of the joint to a level at or below the surfaces of the of the respective first and second current carrying members preventing the buildup of excess weld material at the joint and providing a smooth, flush finish to the surface of the weld material, the joint being constructed substantially of a portion of the first material of the first current carrying member and a portion of the second material of the second current carrying member.
 2. The device, as claimed in claim 1, wherein the electron beam means comprising of an electron beam gun.
 3. The device, as claimed in claim 1, wherein the first and second materials of the respective first and second current carrying members comprising similar material.
 4. The device, as claimed in claim 3, wherein the joint is substantially as conductive as the first and second current carrying members.
 5. The device, as claimed in claim 1, wherein the joint is substantially deficient of any excess weld material.
 6. The device, as claimed in claim 1, wherein the first and second materials of the first and second current carrying members comprising an aluminum alloy.
 7. The device, as claimed in claim 6, further including a shim disposed in the joint, wherein the joint is constructed substantially of the shim, a portion of the first current carrying member and a portion of the second current carrying member.
 8. The device, as claimed in claim 7, wherein the shim comprising an aluminum alloy.
 9. The device, as claimed in claim 8, wherein the first and second current carrying members comprising a 6101 aluminum alloy and the shim comprising a 4047 aluminum alloy.
 10. The device, as claimed in claim 1 wherein the first and second materials of the first and second current carrying members comprising a copper alloy. 